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Remove/install rear window - AR67.20-P-2000Y

MODEL 219.3 

Fig 1: Identifying Rear Window Remove/Install Components (1 Of 3)
G10768298Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Rear Window Remove/Install Components (2 Of 3)
G10768299Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Rear Window Remove/Install Components (3 Of 3)
G10768300Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES

24.6.08 Note on painting in the glazing area added Step 10  
REMOVING Removing     
DANGER Risk of injury  due to tear or warming up of cutting wire and through glass splinters when cutting out glued windows Wear protective gloves and safety glasses. AS67.00-Z-0004-01A
NOTES Notes on remove/install rear window   AH67.20-P-2000-01T
1 Prepare adhesive cartridge IMPORTANT When using 2-component repair kit for installing glued windows.
Cartridge gun		 AR67.10-P-1000-07Y
Repair kit *BR00.45-Z-1015-02A 
IMPORTANT When using 1-component repair kit for installation without booster. AR67.10-P-1000-12SX
SPECIAL TOOL Intermediate piece
Cartridge preheater, cartridge gun		 Figure
Repair kit *BR00.45-Z-1089-02A 
2 Remove roof antenna (A2/49) IMPORTANT Loosen left and right side paneling in trunk until antenna lines and electrical connector on roof antenna (A2/49) are accessible.
IMPORTANT On vehicles as of 1.6.06 the roof antenna (A2/49) is integrated into the roof and must not be removed.		  
On vehicles up to 31.5.06 with code (521) Radio MB Audio 50 USA (without navigation) or with code (525) Radio MB Audio 50 APS or with code (526) COMAND (without navigation) or with code (527) COMAND APS (with navigation) or with code (528) HIGH Class USA or with code (529) HIGH Class Japan or with code (530) COMAND APS USA (with navigation) AR82.70-P-8951TX
On vehicles up to 31.5.06 with code (228) Stationary heater or with code (272) Telephone preinstallation non-networked including telephone antenna or with code (386) Preinstallation for cell phone UPCI system or with code (388) Cell phone UPCI system AR82.70-P-8951TXA
3 Remove paneling from left and right C-pillar   AR68.30-P-4490TX
4 Remove ground line (4) from ground point    
5 Disconnect electrical connectors (5, 6, 7)    
6 Fasten all electrical lines from rear window (2) to glass with tape    
7 Cut out rear window (2) with Roll Out 2004 window removal tool Roll out 2004 window removal tool
Cup suction tool		 AR67.10-P-1000-11SX
8 Remove rear window (2) from body with cup suction tools IMPORTANT Aid of helper required.
Cup suction tool		  
INSTALLING Install     
9 Install roof antenna (A2/49) on rear window (2) with antenna lines (8, 9) IMPORTANT Only on vehicles up to 31.5.06 with code (228) Stationary heater or with code (272) Telephone preinstallation non-networked including telephone antenna or with code (386) Preinstallation for cell phone UPCI system or with code (388) Cell phone UPCI system or with code (521) Radio MB Audio 50 USA (without navigation) or with code (525) Radio MB Audio 50 APS or with code (526) COMAND (without navigation) or with code (527) COMAND APS (with navigation) or with code (528) HIGH Class USA or with code (529) HIGH Class Japan or with code (530) COMAND APS USA (with navigation).
IMPORTANT Ensure that roof antenna (A2/49) and antenna leads (8, 9) are installed correctly.
IMPORTANT On rear window (2) without guide groove in seal (10): Cut into seal (10) in area of roof antenna (A2/49) (arrow). Guide antenna lines (8, 9) through slot and fasten along seal (10).
NOTES Cut only one slot in the seal (10) to prevent leakage.
IMPORTANT On rear window (2) with guide groove in seal (10): Insert antenna lines (8, 9) into guide groove in seal (10) on rear window (2).		  
10 Prepare body flange for installation of window   AR67.10-P-1501-01Y
NOTES General notes about painting the body flange in the glazing area Pay attention to notes concerning the preparation of new parts such as the A-pillar, the roof or the side walls. AH98.00-P-9408-06A
Wet and dry vacuum cleaner  
Repair kit *BR00.45-Z-1015-02A 
Repair kit *BR00.45-Z-1089-02A 
Touch-up pencil *BR00.45-Z-1012-07A 
Hepox 2K EP primer filler 4017 (Spray Max) *BR00.45-Z-1050-07A 
11 Insert rear window (2) with cup suction tools, align and then remove. IMPORTANT Aid of helper required. AR67.20-P-2000-04Y
SPECIAL TOOL Feeler gauge
Cup suction tool		 Figure
Distance between coating of rear window and rear edge of roof *BE67.20-P-1002-01F 
12 Prepare rear window (2) for installation. IMPORTANT Allow primer to air-dry for a minimum of 10 minutes. AR67.10-P-1000-03Y
Repair kit *BR00.45-Z-1015-02A 
Repair kit *BR00.45-Z-1089-02A 
13 Remove protective foil from rubber window spacers. IMPORTANT Window rubber spacers are attached on rear window (2).  
14 Apply adhesive material NOTES Install rear window (2) within 10 minutes, otherwise adhesive force of adhesive material starts to decrease. AR67.10-P-1000-08Y
IMPORTANT Apply adhesive bead uniformly approx. 13 mm high.
Cartridge gun		  
Repair kit *BR00.45-Z-1015-02A 
Repair kit *BR00.45-Z-1089-02A 
15 Insert rear window (2) into body with cup suction tools and install NOTES For this purpose open side window in driver door for duration of curing time. This prevents the rear window (2) from being pressed outwards by the air pressure when a door is closed
IMPORTANT Aid of helper required.
IMPORTANT Center rear window (2) above window cutout on body flange with aid of helper and then position to coincide with strips of adhesive tape
IMPORTANT Position rear window (2) on adhesive bead and press on until it makes contact with rubber window spacer.
IMPORTANT The curing time of the adhesive material is approx. 1 h.
Suction lifting device		  
16 Route antenna lines (8, 9) in trunk and connect IMPORTANT On vehicles as of 1.6.06 the roof antenna (A2/49) is integrated into the roof and it is not necessary to route antenna lines (8, 9) in trunk.  
On vehicles up to 31.5.06 with code (521) Radio MB Audio 50 USA (without navigation) or with code (525) Radio MB Audio 50 APS or with code (526) COMAND (without navigation) or with code (527) COMAND APS (with navigation) or with code (528) HIGH Class USA or with code (529) HIGH Class Japan or with code (530) COMAND APS USA (with navigation) AR82.70-P-8951TX
On vehicles up to 31.5.06 with code (228) Stationary heater or with code (272) Telephone preinstallation non-networked including telephone antenna or with code (386) Preinstallation for cell phone UPCI system or with code (388) Cell phone UPCI system AR82.70-P-8951TXA
17 Connect electrical connectors (5, 6, 7)    
18 Install ground line (4) on ground point    
19 Install paneling on left and right C-pillar   AR68.30-P-4490TX
TEST VALUES FOR LIFTGATE WINDOW, REAR WINDOW

Number Designation Model 219
BE67.20-P-1002-01F Distance between coating of rear window and rear edge of roof mm 5
Fig 4: Identifying Intermediate Piece (000 589 86 63 00)
G10768301Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Feeler Gauge (129 589 03 21 00)
G10768302Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1015-02A Repair kit, glazing, installing window, 2-component adhesive A 220 670 00 93
BR00.45-Z-1089-02A Repair kit, installing window, 1-component adhesive, replaced by: A 221 670 81 01 A 221 670 21 01
BR00.45-Z-1012-07A Primer stick A 000 986 27 50
BR00.45-Z-1050-07A Hepox 2K EP primer filler 4017 (Spray Max) Spies Hecker GmbH
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